Field of the Invention

[0001] The present invention is directed to a steam station or steam generator unit configuration with improved water softening performance during repeated and/or extended steam generation use.

Background of the Invention

[0002] Steam irons are well known as providing a clothes smoothing device comprising a water reservoir within the iron body and comprising a heated sole plate having a surface for contacting clothing. Water may be heated by the sole plate or a separate heater to create steam that can be continuously delivered through holes of the sole plate or may be controlled to be delivered as a response to activation by a trigger or the like or as a result of certain sensed conditions.

[0003] More recently, steam stations have been developed that utilize an iron as such is provided with a heated sole plate but without a water reservoir, wherein the iron is connected with a steam generation base unit that includes a water reservoir and a heating device for creating steam. The steam and usually electrical power are delivered to the iron by way of a steam conduit and electrical wires, respectively, that are provided within a flexible hose that allows the iron the be manipulated independently of the base unit of the steam station.

[0004] Typically, the steam generation base unit and iron device are also physically connectable to one another, such as by a latching mechanism of a mechanical type. The iron is also then releasable from the base unit by unlatching of the mechanism for use. The iron itself of such a steam station is typically designed like a conventional iron having a handle portion to allow manipulation of the iron, in particular its soleplate, for steaming and pressing clothing or the like. As compared with a conventional iron, a stream station including a steam generator can produce a much greater quantity of steam over longer time since the steam is generated within the base unit, which is typically larger than an iron and includes a bigger water reservoir and more powerful steam generator. [0005] A water reservoir of a steam station is typically provided so as to be refillable with water either by providing an access to the reservoir as positioned within the steam station or by providing a removable reservoir. Either way, the reservoir is sized and shaped to hold a sufficient quantity of water based upon the needs for typical usage.

[0006] Prior art steam stations and steam generators have a common shortcoming related to the build-up of minerals within the steam generator components during use in the form of calcification, especially when using so-called“hard” water. Calcium carbonate and other calcium compounds are forms of calcification commonly found in household or business water supplies. As such, when the phase of the water changes to steam (gas) during boiling, the calcium compound can build up as calcification (also referred to as scale, limescale, calcium carbonate, calcium compound, etc.) where the liquid water was vaporized into steam gas by a boiler. Calcification is especially prone to formation on hot surfaces, e.g., surfaces contacting the water as it is boiled. Steam garment care appliances can build up calcification on the boiler surfaces, which over time causes reduced boiler performance and efficiency. Also, calcification solids or precipitate can travel down the steam path and out of the iron, onto the garment.

[0007] As boilers tend to be hottest closest to the various heating elements or heat sources, these areas also tend to suffer from the most calcification. Calcification, when built-up over time, can negatively affect the utility of the steam station’s steam generator, and in some cases clog the steam generator rendering it ineffective. The boiler units, where the majority of calcification tends to occur, also tend to be very difficult to clean (i.e., remove the calcification deposits built-up over time). In fact, many boiler units are hermetically sealed for proper operation, and therefore need to be substantially disassembled to access the internal parts of the boiler, making cleaning difficult and often not able to be accomplished by a user.

Summary of the Invention

[0008] Typical steam generators of steam stations include a water heater, such as a boiler or pre-heater for heating a received fluid, such as water, where most of the calcification build-up occurs during the heating of liquid. This build-up then leads to less direct heating and reduced passage size as the calcification builds-up over time and continued use. The present invention includes a system that reduces calcium carbonate from building up within a heater or boiler of a steam generator. As used herein, a boiler is an example of a water heater. Water heaters can also include pre-heaters and/or any apparatus or element that causes a fluid to become heated. Although the term boiler is used throughout, any instance where boiler is used is understood to also include embodiments of the broader, water heater terminology.

Embodiments also facilitate cleaning of the steam generator components.

[0009] The provision of a non-stick substance, surface, and/or coating to various surfaces of various components reduces build-up of calcification on the non-stick surfaces but increases solids within the steam, water, or any mixture of the two (or other fluid) stream passing through the steam station or steam generator. This can improve functionality and improve longevity of steam stations and steam generator units.

[0010] The present invention includes improvements to a steam station. A first aspect of an improved station includes a steam generator that includes a non-stick substance on inner heater and/or boiler surfaces to reduce formation and adhesion of solids to the inner heater surface and components. A second aspect of an improved steam station includes an in-line filter configuration wherein a filter is located downstream of a heater to collect solids precipitated from the water or other liquid as such solids are present in the fluid flow from the heater. The amount of solids in the fluid flow is therefore increased by the provision of the non-stick substance. Additionally, instead of simply ejecting the calcium carbonate calcification particulate solids (which can be referred to also as“particulates,”“solids,” etc.) onto a garment being ironed, a filter assembly with a replaceable and/or cleanable filter element can be added to the steam generator fluid flow path to filter out the calcification solids flowing out of the heater before exiting the iron. The following describes embodiments of the invention in greater detail. It is noted that like components are labelled with like numerals throughout the several figures.

[0011] A heater (e.g., a boiler) within the steam generator of the steam station can first receive water (or other fluid) from a source where the water is heated, followed by a filtering of the heated, liquid water using a filter that works with the heated water to catch calcium compound solids. The heater raises the water temperature to potentially create steam. Prior to the water reaching boiling temperatures, the water within the heater can be heated enough to cause the calcium compound in the water to precipitate and form the solids, such as solids that form within the heater, including on heater surfaces. As another aspect, adhesion to heater surfaces can be reduced by providing a non-stick substance/coating to the inner surfaces of the heater, reducing the likelihood of solids depositing on the heater surfaces. The solids flow out of the heater and into the filter to be caught therein. The filter catches the solids before they would travel to a material or garment being treated with the steam generator. In some embodiments, a filter can be provided post any heating element, heater, boiler, etc., and in particular, a heating element that is controlled to heat liquid above a temperature causing solids within a fluid to precipitate.

[0012] By including such a filter downstream of the heater where a majority of calcification solids can be caught in operation, solids travel from the steam generator can be minimized. Preferably, a user can clean the steam generator by flushing filtered solids from the filter during filter cleaning instead of descaling the steam generator heater itself. The filter is preferably reusable, so the consumer can remove it, wash out the solids from it, and replace the filter in the steam station appliance for continued use.

[0013] According to a first aspect of the present invention, a water heating apparatus is disclosed. According to the first aspect, the water heating apparatus includes a first water heater including an interior surface and a heating element, where the first water heater is configured to heat water such that steam is produced. The water heating apparatus also includes a first non-stick substance providing at least a portion of the first water heater interior surface, the first non-stick substance configured to reduce adhesion to the first water heater interior surface with respect to a calcium compound within the water, where the calcium compound in the water is caused to flow out of the first water heater as calcium compound solids within a fluid flow. The water heating apparatus also includes a filter assembly in fluid communication with the first water heater to receive the fluid flow and compound solids, the filter assembly including a particulate filter element configured to filter out at least some of the calcium compound solids received within the fluid flow.

[0014] According to a second aspect of the present invention, a method of making a water heating apparatus is disclosed. According to the second aspect, the method includes providing a water heater having an interior surface, where the water heater is configured to heat water such that steam is produced. The method also includes providing a non-stick substance as at least a portion of the interior surface, the non-stick substance configured to reduce adhesion to the interior surface with respect to a calcium compound within the water, where the calcium compound in the water is caused to flow out of the water heater as calcium compound solids. The method also includes providing a filter assembly in fluid

communication with the water heater, the filter assembly including a removable particulate filter element configured to filter out at least some of the calcium compound solids received from the water heater.

[0015] According to a third aspect of the present invention, a method of using a water heating apparatus is disclosed. According to the third aspect, the method includes heating water including a calcium compound at a first water heater that comprises a non-stick substance provided as at least a portion of an interior surface of the first water heater, where the non stick substance is configured to reduce adhesion to the interior surface with respect to the calcium compound in the water. The method also includes causing the heated water to flow out of the first water heater along with at least a portion of the calcium compound. The method also includes filtering the water flowing out of the first water heater using a filter assembly such that at least some of the portion of the calcium compound is filtered from the water.

Brief Description of the Drawings

[0016] Fig. 1 is a perspective view of a steam station in accordance with the present invention comprising a steam generator base and a removable iron that are positioned together.

[0017] Fig. 2 is a perspective view of the steam station of Fig. 1 also showing a flexible hose connecting the iron and steam generator base to facilitate steam passage from the steam generator base to the iron and to allow for electrical connection between them.

[0018] Fig. 3 is a side view of the steam station of Fig. 1 showing the iron positioned to the steam generator base.

[0019] Fig. 4 is a top view of the steam station of Fig. 1 showing the iron positioned within a central zone of a top surface of the steam generator base.

[0020] Fig. 5 is a schematic view of a boiler, a filter assembly, and a pump in perspective as are provided within a steam station of Fig. 1. [0021] Fig. 6 is a perspective view of a boiler, a filter assembly, and a pump of the steam station of Fig. 1, showing features of the top of the boiler, in particular.

[0022] Fig. 7 is a top view of a boiler, a filter assembly, and a pump of the steam station of Fig. 1, showing features of the top of the boiler, in particular.

[0023] Fig. 8 is a bottom view of a boiler, a filter assembly, and a pump of the steam station of Fig. 1 with an example fluid flow path and connections, showing features of the bottom of the boiler, in particular.

[0024] Fig. 9 is cross-section, perspective view of a boiler, a filter assembly, and a pump of the steam station of Fig. 1 with a filter shown removed from a respective filter housing, according to various embodiments.

[0025] Fig. 10 is a perspective exploded view of a boiler, a filter assembly, and a pump of the steam station of Fig. 1.

[0026] Fig. 11 is a perspective assembled view of a boiler of the steam station of Fig. 1, according to various embodiments.

[0027] Fig. 12 is a high-angle perspective exploded view of a boiler of the steam station of Fig. 1, according to various embodiments.

[0028] Fig. 13 is a low-angle perspective exploded view of a boiler of the steam station of Fig. 1, according to various embodiments.

[0029] Fig. 14 is an exploded view of a filter of the steam station of Fig. 1, according to various embodiments.

[0030] Fig. 15 is a perspective view of a pre-heater and filter combined assembly for use in a steam station, according to various embodiments.

[0031] Fig. 16 is a cross-sectional schematic view of the pre-heater and filter combined assembly for use in a steam station, according to various embodiments

[0032] Fig. 17 is a side exploded cross-section view of various decalcification components of a steam generator for use with a steam station that includes a pre-heater and an operative fluid flow and schematic control diagram, according to various embodiments. [0033] Fig. 18 is a flowchart of a process, according to various embodiments.

Detailed Description of the Preferred Embodiments

[0034] The present invention is directed to a steam station that includes a steam generator within a base unit that includes one or more improved anti-calcification features. Existing steam stations suffer from accumulation of calcification on components, leading to reduced steaming performance. An improved, decalcifying steam station, which can include a steam generator base and an iron are disclosed, through which steam can be applied to a garment.

As used herein, water is an example use of a fluid to be softened, filtered, and/or distributed during steam station use. Many other fluids, liquids, and other substances are also contemplated herein.

[0035] Water commonly used in steam stations often includes elements of hard water. One common element in hard water is calcium carbonate, the build-up of which is a common limiting factor to the efficiency, performance, and usable life of present steam stations. The terms“steam generator” and“steam station” can be used interchangeably, but the term steam station herein is intended to refer to an entire assembly that include a steam generator base unit and a an iron that is used to apply steam produced within the steam generator.

[0036] A steam station 10, as illustrated in Fig. 1, is useful for steaming garments and the like, wherein the steam generator base 12 can provide significantly more steam in quantity and flow rate to the iron 14, as compared with a conventional steam iron. A steam station 10 of the present invention provides desirable steam production by way of a unit with improved anti-calcification (i.e., descaling, or anti-scale) performance.

[0037] The steam generator base 12 is shaped to support the iron 14 on a top surface 16 thereof. Preferably, the top surface 16 is inclined to position the iron 14 in an ergonomic position for a user. The steam generator base 12 also preferably houses a number of operative components to provide a supply of steam from the steam generator base 12. Specifically, a water reservoir 18 provides a refillable supply of water that can be turned into steam. It is preferable that the size of the water reservoir 18 be sufficient to supply a desired quantity of steam at a desired rate from the iron 14, as discussed more in detail below.

[0038] The water reservoir 18 is also preferably removable from the steam generator base 12 for filling and refilling with water. However, in other embodiments, the water reservoir 18 is non-removably fixed to the steam generator base 12. In the shown embodiment, the water reservoir 18 comprises a slidable component, like a drawer, that is slidably supported to move within the steam generator base 12 and to be removable for filling. Slide components (not shown) can include commercially available slide devices that can be mounted within the interior of the steam generator base 12, or the steam generator base 12 can be formed with integral components that provide slide bearing surfaces to guide the water reservoir 18 within the steam generator base 12. Otherwise, the water reservoir 18 can simply be removed from the steam generator base 12, which action may require manipulation of a latching

mechanism, or the removal of a component for access or not. As shown, the water reservoir 18 can be formed with a handle portion 20 that allows for easy manipulation of the water reservoir 18 to and from the steam generator base 12. The water reservoir 18 can also be transparent, as illustrated, so that a water level therein can be easily ascertained.

[0039] Also within the steam generator base 12, the water reservoir 18 is operatively fluidly connected with a steam generation and/or boiler components (for example boiler 512, an example of a water heater, is described in more detail below with respect to Figs. 5-13), the function of which is to heat and boil water from the water reservoir 18 and supply steam from the steam generator base 12. A fluid transport hose can fluidly connect the water reservoir 18 to the boiler in order to supply water to the boiler 512. Fluid connection to and from the boiler can be accomplished with conventional hoses, connectors, clamps, and the like for handling the fluid transport of water and steam, respectively. The boiler components can be fixed within the interior space of the steam generator base 12 in any known or developed manner.

[0040] The boiler 512 can also be conventionally controlled. A controller or control unit 501 may be included in the steam generator base 12 at any suitable location, which control unit can be used to control the quantity and/or rate of steam production. As shown with respect to Fig. 5, the controller 501 can be in operative communication with a water pump 510, the boiler 512, and/or a filter assembly 514. The controller 501 can set a temperature of a heating element (e.g., 1012 shown in Figs. 10 and 13), a duration of temperature exchange, a quantity of water supply and/or flow rate, among other things. In some embodiments, a user control 26 can be configured to change various parameters of the controller 501 including by reference to those parts above here showing connected control components. The steam generator base 12 is also preferably connectable to a power source, such as conventional line power or electricity, by a cord or the like to provide electrical power to operate the control unit, the boiler 512, any pumps (such as water pump 510) or the like, and preferably also to the iron 14, as discussed below. A power cord can be accommodated within a portion of the steam generator base 12 as shown at 21. Cord reels and the like can be incorporated as desired.

[0041] Connected between the steam generator base 12 and the iron 14 can be a flexible hose 22 that preferably provides a conduit within which both a steam transport line and an electrical cord can be contained. The flexible hose 22 can utilize conventional connectors, clamps, and the like to make the appropriate connections with the steam generator base 12 and the iron 14. A steam transport line (not shown) can be operatively fluidly connected, as discussed above, with the boiler 512 within the steam generator base 12 and can also be operatively fluidly connected with an interior space of the iron 14 in any conventional manner. From the interior of the iron 14, steam can be delivered through the iron’s soleplate 24 by way of steam holes, as such are also conventionally known. Electrical power is preferably delivered from the steam generator base 12 (as such can be operatively connected to power) to the iron 14 by the electrical cord. Electrical power can be used to heat the soleplate 24 and to provide control power to an iron control unit having a user control 26, for example, for setting the desired temperature of the soleplate 24. A trigger 28 is also preferably provided for selectively delivering steam from the soleplate 24, which triggers and delivery control elements are also well-known.

[0042] A length of the flexible hose 22 provides a range of movement of the iron 14 relative to the steam generator base 12. This allows a user to move about a garment or the like from a single position of the steam generator base 12. A handle portion 30 of the iron 14 provides a gripping feature for a user to manipulate the iron 14. A hose bracket 23 can be provided from the steam generator base 12, for example, to facilitate stowing of the hose 22, especially during any movement of the steam station 10.

[0043] With reference to Fig. 5, an improved fluid transfer and delivery system is shown for handling a conversion of liquid, such as water, to gas, such as steam, and for delivery of the steam for usage. According to various embodiments, a component configuration for a fluid transfer and delivery system (shown schematically in Figs. 5-10) can include the water pump 510, the boiler 512, and the filter assembly 514. The water reservoir 18 can supply water to various components of the system located downstream of the water reservoir 18. A fluid or gas, such as various physical states of water, can leave the system at exit 820 (see Fig. 5). Water can flow downstream through the steam generator through various fluid conduits 810, 812, 814, and 816 that each can fluidly connect the various components as shown in particular with respect to Fig. 5. Figs. 6- 10 show the water pump 510, the boiler 512, the filter assembly 514, and various components thereof in fluid communication and in several views.

[0044] Water begins in reservoir 18 and can be caused to be operatively pumped or caused to be moved downstream along operative or fluid connections or conduits (810, 812, 814, and 816) provided between the various components, and the water pump 510 may preferably be located between the water reservoir 18 and the boiler 512. Water pump 510 (and/or other pump[s]), operatively supported within steam station 10, can be located elsewhere along the flow path so long as water/steam flow is provided from water reservoir 18 through to exit 820, as needed or applicable for suitable fluid flow. During operation of steam station 10, the water pump 510 can operatively cause water to flow downstream from the water reservoir 18 to the boiler 512, whereby the water can be caused to boil and to controllably change phase or condition, becoming steam and/or water vapor are (referred to generally as steam, herein).

The water pump 510 can run continuously, as needed for a batch, or otherwise as suitable and can be controlled and operated by controller 501.

[0045] A water reservoir 18, as used in Fig. 5, can include a suitable fillable water source, as applicable and discussed above. As shown in Fig. 5, a water reservoir 18 is fluidly connected and in fluid communication with water pump 510 via pump inlet 516 and fluid conduit 810 (or operative connection). The water reservoir 18 and/or fluid conduit 810 can also include various components, such as additional pumps, filters, junctions, heaters, etc. Water received at the water pump 510 can be motivated or propelled downstream by various motors and pump components, causing water to continue downstream to the boiler 512 through a pump outlet 520 and fluid conduit 812. The water pump 510 can also include a pump housing 554 having electrical pump contacts 518, as shown.

[0046] The water pump 510 can include a pump housing 554 and a pump motor (not shown), which can be an electric motor, preferably. The water pump 510 can be controlled by a user or other control system such as controller 501, according to various embodiments. For example, the water pump 510 can be activated by controller 501 in order to pump water into the boiler 512 when the boiler 512 is empty, low, or when a user has begun using the steam station 10, among other circumstances.

[0047] With reference to Figs. 5 and 6, the water pump 510 is fluidly connected to receive a flow of water from the water reservoir 18 via fluid conduit 810, e.g., by gravity, draw, or pump. In some embodiments (not shown), the water pump 510 can be omitted from steam generator or steam station, and other non-pump functionality, such as gravity-based fluid propagation and the like, can be used to move fluid between the various components. As described herein, a water pump 510 is described, but various embodiments described herein are understood to use the water pump 510 as one example of a component that includes fluid movement or propagation functionality.

[0048] The water pump 510 causes the received water to flow to the boiler 512 through fluid conduit 812. The boiler 512 then operatively raises the water temperature to preferably a boiling temperature (e.g., about 100 degrees Celsius [°C] or above). The received water can include water having various degrees of“hardness,” including various levels of minerals or other compounds. Water hardness can be defined in terms of the quantity of calcification based on volume or weight of solids, minerals, etc. as a ratio of an amount of water being received. In some embodiments, the boiler 512 is configured to maintain at least some steam when the steam station 10 is not in active use. In other embodiments, the boiler 512 is configured and controlled to produce steam only when in active use by controller 501.

[0049] Still referring to Fig. 5, the water pump 510 is shown in fluid communication with the boiler 512 located downstream, via fluid conduit 812 (or other operative connection). The fluid conduit 812 is connected to the pump outlet 520 and the boiler inlet 530 of the boiler inlet fitting 531. As shown in an exploded view in Fig. 10, boiler 512 includes a boiler housing 536, a boiler cover 534, boiler cover fasteners 524, a boiler cavity (or chamber) 920 (see Fig. 9), and a boiler heating element 1012. Boiler inlet fitting 531 can be configured to be threaded into a threaded boiler inlet fitting hole 1011 of boiler cover 534, according to various embodiments (see Fig. 10). The illustrated boiler heating element 1012 can be as shown, or can be configured differently. In some embodiments, the boiler heating element 1012 is located outside the boiler cavity 920, but in contact with the boiler housing 536. The heating element 1012 can include Calrod, resistive-type electrical heating device(s), gas- based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. Preferably, the heating element(s) 1012 will be controllable so that water contained in the boiler 512 will reach the boiling point of water to generate steam.

[0050] Depending on configuration, steam station 10 can operate on one of at least two steam delivery principles. Steam may be generated by the boiler 512 so as to be directed to an iron 14 for direct use. Alternatively, steam can be accumulated and stored for later use, as may be desired. For example, steam can accumulate in the boiler 512 or elsewhere until the user activates a steam-releasing function causing the steam to exit the iron 14.

[0051] The water pump 510 can take any form of a suitable fluid pump, including but not limited to various forms of a positive displacement pump, an impulse pump, a velocity pump, a gravity pump, a steam pump, a valve-less pump, an electromagnetic vibration (EMV) or other linear pump, any combination thereof, or any other suitable pump that can deliver a desired volume and flow rate of liquid to the boiler 512 for use in a steam generator such as steam station 10. More specifically, during operation of the boiler 512, at least some water received may remain in the liquid phase (i.e., not be boiled into gaseous steam), according to various embodiments. In other embodiment, substantially all water received at the boiler 512 can be boiled into steam. In various embodiments, additional water pumps similar to water pump 510 can be utilized for assisting in the fluid flow of either the water or steam as may be desirable or necessary during steam station 10 operation.

[0052] In more detail, as water is pumped downstream from the water pump 510 reaches the boiler 512, the water can completely or partially fill the boiler cavity 920 defined by an interior of a boiler upper portion 534 and lower portion 536. As shown in Figs. 10 and 13, the example of a boiler heating element 1012 is approximately shaped as a coil or spiral, and is attached to a lower side of boiler 310 lower portion 536. In this case, heat from heating element 1012 is conducted through the lower portion 536 to heat the water within boiler 512. In some embodiments, the location of the heating element 1012 (whether inside or outside the boiler 512 itself) can affect the heating distribution of the water contained in the boiler 512 at a particular point in time. Heating element 1012 can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. Heating element 1012 can include a heating element connection 526, as shown in Fig. 8. Preferably, the heating element 1012 (or elements) is controllable so that water contained in the boiler 512 will reach a boiling point, but may also be heated to various other temperatures. Boiler 512 can receive electrical power for use in heating from boiler contacts) 538, as shown in Fig. 8.

[0053] The boiler 512 can be configured to maintain an amount of steam when activated, awaiting only a user’s activation of steam through the steam generator controls or switches, and having a nearly instant supply of steam when desired. In alternative embodiments, the boiler 512 can remain idle when the user is not steaming garments, or may merely pre-heat the water while awaiting further control prior to heating water contained in the boiler cavity 920 to the boiling point of water (e.g., 100 °C at standard atmospheric pressure). In some embodiments, the boiler 512 can receive about 10-40 grams (or milliliters) of water from water pump 510 at a time, as a cycle. In other embodiments, the boiler 512 can operatively receive a constant or steady supply of incoming water and can continuously heat the water to create steam.

[0054] The boiler 512 can also include a steam exit housing 522. Steam can be caused to exit the boiler 512 via boiler outlet fitting 1010 and boiler outlet 550 of a steam exit housing 522 having a steam exit cover 528. The boiler outlet 550 can be in fluid communication with a steam exit 820 via fluid conduit 806. Steam exit 820 can be connected, for example, to an iron 14, whereby the steam can be applied to a garment. As described herein, a filter assembly 514 can be provided in fluid connection to the boiler 512 in order to trap and gather solids from water/steam before or after boiling. The steam preferably has little to no calcium compound solids that reach the garment from the steam station 10 after passing through filter assembly 514, as described below. If the iron 14 of steam station 10 is present, the iron 14 may have a control function whereby a user can choose a free flow or steam or a set steam cycle. In other embodiments, the steam flow may be determined automatically, for example, based on preset parameters or circumstances.

[0055] The steam exit housing 522 of the boiler 512 can also include a steam bypass exit 532. Steam bypass exit 532 can be set to relive pressure of boiler 512 in a case of boiler 512 pressure that exceeds a pressure threshold. The pressure threshold can be set based on suitable pressure based on a configuration of boiler 512 by way of a pressure valve where steam pressure exceeds a set pressure, e.g., set either mechanically or electronically using controller 501. Preferably, steam from boiler 512 will exit through boiler outlet 550, but in some cases, steam can also exit boiler 512 through the steam bypass exit 532. The steam exit cover 528 attached to the steam exit housing can be fastened using fasteners 552, which can include screws and/or bolts according to various embodiments. Fasteners 552 can preferably tightly secure the steam exit cover 528 to the steam exit housing 522.

[0056] Steam, temperature, and other forms of control systems (including controller 501), can be included to manage and maintain a desired water temperature and/or pressure within the boiler 512. For example, using various control systems, water temperature can be determined (and the water heated) as a function of heat applied to a present, past, or future flow rate of water. In preferable embodiments, the water can be operatively heated in a continuous heating process at the boiler 512 meaning the water can enter the water pump 510 and boiler 512 at a supplied temperature (e.g., ambient) from the water reservoir 18 and at a flow rate, the water can be heated as it flows through or along the boiler 512 at the flow rate, and the water can exit the boiler 512 at a desired or preset temperature to cause precipitation of the calcium carbonate particulates/solids from the water at the same flow rate.

Alternatively, the water can be heated in stages or all at once as the water is supplied at a desired volume on a cycle-by-cycle basis.

[0057] Once water received from water reservoir 18 is caused to be heated at boiler 512, the boiler outlet 550 may fluidly communicate the water and proceed to flow to filter assembly 514 by fluid conduit 814, as shown in Fig. 10. The water can enter the filter assembly 514 by filter inlet 540, and the water may then pass through filter housing 542, and filter element(s) 916, which may preferably be supported by filter structure 918 having filter structure support members 1014 with water-passable gaps defined thereby and located therebetween. Filter element(s) 916 can preferably filter water, steam, or mixtures thereof of calcification as the fluid passes through the passable gaps of filter structure 918 and filter structure support member 1014. The filter element(s) 916 themselves can include pores or openings sized between 20 and 200 microns, as described herein, such that the pores or openings are configured to filter solids from the fluid passing therethrough. Any number of filter structure support members 1014 can be included in filter structure 918. The fluid can then pass out of filter assembly 514 through filter exit 546 through fluid conduit 816. [0058] As shown in more detail with respect to Figs. 9 and 10, an example filter assembly 514 can include one or more filter elements 916 and filter structure 918 that together can be removed from the filter housing 542 as a cartridge unit. The filter elements) 916 (and optionally the filter structure 918) can then be emptied of water and/or filtered calcification, rinsed, cleaned, and/or washed, and replaced into filter housing 542 for continued use. In one embodiment, simply removing the filter element(s) 916 and filter structure 918 cartridge unit from the filter housing 542, turning them over, and running tap water over the unit can substantially empty and clean the filter components.

[0059] The filter element(s) 916 can include a stainless steel (or similar) metal mesh component, and may have a mesh pore size of about 20-200 microns, such as 20, 50, or 100 microns, in various embodiments. A preferable pore size of a metal mesh filter element 916 can be sized at 35 microns in various embodiments. The size of the mesh openings can be smaller or larger, but is preferably sized based upon the effective size of the precipitate that results from the boiling of water in boiler 512.

[0060] In accordance with an aspect of the present invention, one or more surfaces of the boiler 512 is provided to be non-stick. In some embodiments, boiler 512 is constructed of materials that lack non-stick properties, such as cast aluminum or stainless steel. A non-stick substance (such as a coating) can therefore be caused to be applied to some of or all of the boiler’s 512 interior surfaces of the boiler cavity 920 that contact fluid being heated during use. In some cases, a boiler cavity 920 includes a non-stick substance on all interior surface except a top, where gravity can make a build-up of calcification or other solids less likely. In a case where the non-stick substance is a coating, the coating can be applied to the boiler cavity 920 through various known forms of coating deposition.

[0061] By applying a non-stick substance to various water/fluid heating components, such as the boiler 512, the useful lifespan of the steam station 10 and components thereof can improve. As described herein, one or more filters can operate to collect solids that do not stick to the boiler 512 and exit the boiler 512 accordingly. In particular, the boiler 512 can see increased useful life as calcification solids will be less likely to accumulate on the interior walls of the boiler cavity 920. Accumulated calcification solids presently reduces a boiler’s performance and lifespan. A boiler, such as boiler 512, if otherwise strained by excessive calcification build-up, can become overworked, overheated, or otherwise malfunction or wear. By reducing calcification build-up in the boiler 512, and instead catching the calcification solids in the filter assembly 514, the filter assembly 514 can collect the calcification solids, in a unit specifically configured to do so.

[0062] In accordance with the present invention, a non-stick surface is one that is less conducive to deposition of calcium compounds to a heater surface than the material of a typical heater, such as various metals. The terminology“non-stick” is used herein with reference to various surfaces, walls, interiors, components, materials, substances, etc. within this disclosure. Non-stick can refer to one or more characteristics of such substances, etc. In general, it is understood that non-stick can refer to a substance, which can include a coating of a substance applied to another ordinary substance that is not non-stick. Generally speaking, a non-stick substance is defined as having a low or very low coefficient of friction, but can include substances having a coefficient of friction that approaches zero. In other words“non stick,” although implying no adhesion whatsoever on its face, may not completely eliminate friction or stick altogether, as is known in the art. One well-known non-stick substance is a polytetrafluoroethylene (PTFE) polymer, also known by the trade name of“Teflon.” Many other examples of non-stick substances exist and can be employed in various described embodiments.

[0063] As used herein, a means for making a component, surface, or substance into a nonstick surface includes producing a component (and/or coating an existing component) with a non-stick substance. Such non-stick substances include PTFE, ceramics, anodized aluminum, silicone, enameled cast iron, superhydrophobic substances, and/or any substance that has a low coefficient of friction. Non-stick substances also include substances that are less prone to adhesion of particulate matter such as calcification and/or that have a low propensity for nucleation at the surface of the substance. Various non-stick substances can be employed as “food-safe” in food processing service apparatuses like coffee makers and the like, while other embodiments may not.

[0064] Heaters are made of materials designed for efficient heat transfer properties during a heating process. Such materials commonly include various metals, which are not typically non-stick materials. Examples of such typical substances that lack non-stick properties can include metals, such as some forms of aluminum (die-cast aluminum), iron, steel (e.g., stainless steel), and silica, among many others. A common characteristic of non-stick substances is that these substances have properties making them relatively not conducive to surface nucleation, whereas substances that lack non-stick properties generally include a surface that is relatively conducive to nucleation, and therefore build-ups of substances such as calcification.

[0065] A coefficient of friction (COF) is a dimensionless scalar value (typically shown in terms of m) which describes the ratio of the force of friction between two bodies and the force pressing them together. The coefficient of friction depends on the materials used. Some substances have a low coefficient of friction with respect to other substances. For example, ice on steel has a low coefficient of friction, while rubber on pavement has a high coefficient of friction. Coefficients of friction range from near zero to greater than one. At a micro level, friction (kinetic or static) between two substances (or two of the same substance) is affected by surface asperities (unevenness or roughness of a surface) on each respective substance. Asperities that can lead to increased friction can also lead to increased propensity of a surface for nucleation, for example, of various calcium compounds. Therefore, a surface with a lower COF can also have a lower propensity for nucleation in some cases.

[0066] COFs for various substances are known, although variation in practice is common and care should be taken when approximating a COF between two substances. For the purposes of the example below, it will be assume that the friction is dry friction, without a lubricant between the two substances. For example, aluminum-aluminum friction is typically between m=1.05 and m=1.4 (static or kinetic). And steel-steel friction is typically between m=0.42 and m=0.78. Steel-aluminum friction can be about m=0.47 to m=0.61. In contrast, PTFE (Teflon)- PTFE is typically about m=0.04, or roughly one-tenth the COF of two metals. As PTFE is an example non-stick substance as used herein, it is also noted that steel-PTFE is also, likewise about m=0.02 to m=0.20. Therefore, using a non-stick substance can reduce a COF with respect to various substances, even substances that would otherwise have higher COFs.

[0067] Therefore, as used herein, a non-stick substance can be defined in some embodiments, as a substance that has a COF such that a m with respect to various metals such as aluminum or steel is about less than m=0.40, and more preferably m=0.20 or less. In even more preferable embodiments, a non-stick substance can have a COF of m=.10 or less with respect to various metals, such as aluminum or steel. In more preferable embodiments, a non-stick substance can have a COF of m=.05 or less with respect to various metals, such as aluminum or steel.

[0068] With reference to Fig. 9, boiler 512 includes the boiler cavity 920, which can contain a boiler dome 910. Boiler dome 910 can be configured to assist in the formation of steam within boiler cavity 920, and can be a separate component from boiler housing 536 and boiler cover 534. Boiler dome 910 can be formed and shaped to be conducive to boiling of water into steam within the boiler 512, and a dome shape can reduce calcification build-up on walls, e.g., by having fewer crevasses or comers in which particulates can become lodged, and can include internal surface area to assist boiling performance in some embodiments.

[0069] In some embodiments, the various steam generator components (e.g., filter assembly 514, water pump 510, or boiler 512) can contain and hold varying amount of air or non-steam gas. For example, following heating or boiling of water at least partially into steam at boiler 512, the heated steam/water can proceed to filter assembly 514. The filter assembly 514 can be operated even when not fully filled with the heated steam/water if necessary. In various embodiments, the system can be completely or substantially filled with H ₂ 0, including water, water vapor, and/or steam in various locations. However, some air can be present in the steam generation system where steam is not present and therefore, although a fluidly-full system may be optimal for pumping or steam generation performance.

[0070] In a case where water is in the process of heating within the boiler 512, dissolved calcium carbonate or other calcium compounds already existing in the received water can precipitate and form particulate solids within the heated, and eventually boiling, water. Solids tend to deposit and build-up on various interior surfaces or walls of boiler 512. Some solids also can stay within the steam flow from the boiler 512. Traditional boilers are formed of metal (such as steel, etc.), lack a non-stick substance, and are prone to calcification solids build-up at least partially caused by the separation of the pure water (H ₂ 0) from other substances (e.g., CaC0 ₃ or CCa(¾) during a fluid heating and boiling process.

[0071] Referring back to Fig. 5, once the water has been filtered by filter assembly 514 and the calcification solids are removed from the water, the water can exit filter outlet 546 and exit the system at exit 820. The filter outlet 546 can be configured to be in fluid

communication with the exit 820 by fluid conduit 816, which can include a hose or other suitable fluid conduit. [0072] With reference to Figs. 11-13 in particular, the boiler 512 can be assembled in part using one or more boiler cover fasteners 524 that can be threaded bolts or screws and can be configured to be threaded into boiler housing 536 and/or boiler cover 534. The boiler cover fasteners 524 can also take other fastening forms, including adhesives, epoxies, and other forms of fasteners known in the art, such as clips, pins, detents, etc. In preferred

embodiments, the boiler cover fasteners 524 can be tightened such that the boiler housing 536 and the boiler cover 534 form a substantially or entirely hermetically sealed assembly, with the exception of various boiler inlets and/or outlets, as described herein.

[0073] With respect to Fig. 12, a non-stick substance 912 on an interior surface of boiler 512 can reduce sticking of calcification flakes or solids to the boiler 512 during or after formation. In other words, the calcium compounds found in the water being heated is preferably kept from sticking to coated surfaces so as to remain in the water, but converted from a dissolved form to a particulate solid form, suspended in the heated water.

[0074] In embodiments, the non-stick substance 912 may be a coating applied to the walls of the interior cavity 920 of the boiler 512 to resist precipitated calcification from adhering to the walls of the boiler 512. The filter assembly 514 is operatively located after the boiler 512 so it can trap and collect the solids from the heated water, preventing them from entering the steam generator or of the steam station 10 or reaching the iron 14 (and any material being ironed thereby). A similar non-stick substance can also be applied to various pre-heaters as described below in various embodiments, and can be accompanied by a filter assembly following the pre-heater, which is some cases means there would be two filter assemblies within a single steam station 10.

[0075] Also, additional or substitute filters, filter housings, and other water treatment components can be included within steam station 10, such as a filter assembly 514. Examples of filters for use win the filter assembly 514 can include cylindrical, planar, and various other suitable shapes, sizes, and types of filters, especially filters configured to separate calcium compound solids, limescale, or other calcification from water being filtered. Filters, as used herein, can preferably include three-dimensionally usable filters, where a total amount of filtration can be a function of the volume of the filter elements of the filters in use. Examples of filters, as used herein, as described in more detail below. [0076] The combination of the non-stick coated/composed boiler 512 and filter assembly 514 that follows may also reduce the likelihood of calcification solids travelling to the iron 14 (e.g., exit 820) and clogging up fluid flow within, related thereto, or other aspects of the iron 14, its sole plate holes, or discoloring the garments. Advantageously, the filter assembly 514 (specifically the filter element 916 and filter structure 918 within the filter housing 542) can be cleanable and reusable, so the so the consumer does not need to purchase or procure consumable resin packets or devices. Alternatively, the filter element 916 can be consumable and/or replaceable. Filter structure 918 preferably supports a number of filter elements 916, which can comprise mesh panels in an arrangement around the filter structure 918 for particulate solid filtration from the water.

[0077] As above, the mesh size of the filter elements 916 can be based on solids size. In preferred embodiments, water including solids can operatively flow from an inside of filter element 916 to outside, where the water reaching the outside of the filter element 916 will have its solids already filtered out of the water. In this way, solids will be captured within and potentially fill the inside volume of the filter element(s) 916 and filter structure 918 cartridge unit. In other embodiments, the filter assembly 514 is not intended to be cleaned by a user, and can be replaced once a useful filter life has been reached. In some embodiments, the controller 501 can indicate to a user that a new, replacement filter should be inserted into the steam station 10 for optimal performance.

[0078] Various components of stream generator 10 are described in greater detail, below. Although not shown, other components, including known components and configurations, can also be included in the various component configurations (e.g., 500) of steam station 10. In other embodiments, the components shown in Figs. 5-10 can be employed in diverse other steam generation and/or boiler units (e.g., boiler 512) and systems.

[0079] Fig. 11 is a perspective assembled view of a boiler 512 of the steam station 10 of Fig. 1, according to various embodiments. Boiler 512 is shown in greater detail, including steam exit housing 522, steam exit cover 528, fasteners 552, boiler inlet 530, boiler inlet fitting 531, steam bypass exit 532, boiler cover 534, boiler cover fasteners 524, boiler lower portion 536, and boiler outlet 550.

[0080] Fig. 12 is a high-angle perspective exploded view of a boiler (e.g., boiler 512) of the steam generator of Fig. 1, according to various embodiments. Fig. 12 includes a view similar to the perspective view of Fig. 11 of boiler 512 and various components thereof, but shows an exploded view of the various components. In particular boiler dome 910, boiler cavity 920 (having a boiler interior wall), non-stick substance 912 are shown in Fig. 12 that are not shown in Fig. 11. Fig. 13 is a low-angle perspective exploded view of a boiler 512 of the steam station 10 of Fig. 1, according to various embodiments. The view of Fig. 13 is a low- angle view similar to the view of Fig. 12. Also shown in Fig. 13 are heating element 1012 and boiler contacts) 538.

[0081] Fig. 14 is an exploded view of a filter assembly 514 of the steam station 10 of Fig. 1, according to various embodiments. Shown are filter housing 542, filter inlet 540, filter assembly mounting tabs 556, filter outlet 546, filter bypass exit 548, filter structure 918, filter structure support members 1014, filter removal spline 1410, and filter cover 544.

[0082] Still with reference to Fig. 14, the various filter assembly 514 components can form a cylindrical, inside-out water flow configuration (described above), as shown. Alternatively and not shown, outside-in water flow configurations are also contemplated in various embodiments. Filter assembly 514 can also include a filter bypass exit 548, as shown. Filter bypass exit 548 can be configured to relieve water and/or steam pressure from within filter assembly 514. Filter assembly 514 can include filter assembly mounting tabs 556 for mounting of filter assembly 514 within various steam generator base 12 configurations and arrangements, and mounting tabs 556 can include any number or arrangement of suitable mounting tab 556 configurations, including no tabs in some embodiments. As shown in Fig. 14, filter structure 918 can also include a filter removal spline 1410 configured to receive filter cover 544. Filter removal spline 1410 can be shaped and configured to permit threaded filter element 916 removal from filter housing 542, according to various embodiments.

[0083] In other embodiments, filter assembly 514 may take any other suitable shape, such as a flat, planar filter configuration, among others. Filter element(s) 916 can be sized and configured to have a maximum water flow rate that exceeds typical need when the filter element 916 is relatively free of calcification solids in to allow for cases where filter element 916 is partially clogged with calcium carbonate (or other calcification) solids caught in pores ofthe filter element 916 (e.g., pore size of 20-200 microns or other suitable pore size). In some embodiments, the filter assembly 514 has a filter volume that fills with solids as the solids are filtered from the water flowing through filter assembly 514. [0084] Preferably, filter structure 918 and filter element 916 are removable as a unit from filter housing 542, whereby the filter components can be emptied, cleaned, rinsed, and/or washed by a user or consumer. After removing and cleaning the filter components, the filter element 916 and filter structure 918 can be replaced back into the filter housing 542 of filter assembly 514. In alternative embodiments, various replacement components (e.g., filter element 916 and filter structure 918) can be purchased and/or replaced in place of cleaning, especially, e.g., if the particular parts have been in heavy use or been in use for substantial amounts of time.

[0085] Figs. 15 and 16 show an alternative embodiment with a pre-heater 1514 and filter assembly 1516 as a single, combined assembly 1500, according to various embodiments. Various benefits can stem from combining various components into combined assemblies, such as simpler manufacturing, lower costs, more efficient use of space, and the like.

[0086] Fig. 15 is a perspective view of a pre-heater and filter combined assembly 1500, and Fig. 16 is a cross-sectional schematic view of the pre-heater and filter combined assembly 1500, according to various embodiments.

[0087] The shown combined assembly 1500 includes both a pre-heater 1514 and a filter assembly 1516. As used herein, a pre-heater is another example of a water heater, as a boiler is also an example of a water heater. Any instances of the use of boiler or pre-heater can be understood to also refer to water heater, and/or boiler/pre-heater as appropriate. Pre-heaters, especially pre-heaters coated with or composed of non-stick substances, such as pre-heater 1514, can be and operate similar to a boiler, such as boiler 512 above. Combined assembly 1500 as shown is composed of various sub-components, which can be related to or similar to other similar components described with respect to FIGS. 5-14 or 17, herein. Although the combined assembly 1500 as shown include the pre-heater 1514 and the filter assembly 1516, various other components can be similarly combined into single assemblies, such as various boilers, pumps, conduits, etc. in various combinations. In some embodiments combined assemblies can include more than two components (e.g., pumps, filters, heaters, etc.), such as three or more components in a single assembly.

[0088] As shown, the filter assembly 1516 includes a filter structure 1538 that can include a filter element as described in other embodiments herein. As described with respect to various embodiments herein, the filter assembly 1516 (and/or any constituent parts thereof, such as filter structure 1538, filter member 1540, a filter element, etc.) can be cleanable and reusable or can be disposable, depending on preferences. The filter structure 1538 can be connected to an intermediate filter member 1540, which can be operatively connected to an upper filter member 1530 and a filter handle 1510. As shown in particular with respect to FIG. 16, the upper filter member 1530 can be operatively connected, such as by threading, to a filter housing collar 1528. A filter exit 1520 can be used to operatively connect the combined assembly 1500 to other components within a steam system.

[0089] Preferably, prior to being filtered, a fluid such as water and/or steam can be pre heated at pre-heater 1514 that includes a non-stick substance (e.g., as a tube or other unit of a material having non-stick properties, a non-stick substance, and/or a non-stick coating, etc.) on a pre-heater chamber 1534 interior surfaces, walls, or any part of the pre-heater chamber that could come in contact with fluid to be heated prior to filtering at the filter assembly 1516. Pre-heater 1514 can include a heating element 1536, which can be similar to heating element 1012. Heating element 1536 can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating elements), combinations thereof, among other types of heating elements, as known in the art or developed. The heating element 1536 can be heated to approximately 120-160 °C in preferred embodiments, which can represent a temperature higher than a fluid being heated within the pre-heater chamber 1534.

[0090] The pre-heater 1514 can also include a fluid intake 1524 which can be mounted to the pre-heater 1514 by a lower plate 1522. Preferably, after fluid is heated at pre-heater 1514, fluid exits the pre-heater 1514 and passes to the filter assembly 1516 via passage 1532, which can form an integral part of the connecting bridge 1512 of the combined assembly 1500. Passage 1532 can represent an operative and/or fluid connection as described herein. As fluid passes through the pre-heater 1514, solids can precipitate as described herein, pass out of the pre-heater 1514 and be filtered and caught in the filter assembly 1516.

[0091] Fig. 17 is a side exploded cross-section view of various decalcification components 1700 of a steam generator for use with a steam station that includes a pre-heater and an operative fluid flow and schematic control diagram, according to various embodiments.

[0092] Applicant hereby incorporates by reference PCT application number

PCT/US 18/36620 filed June 8, 2018, in its entirety for all purposes. [0093] According to another set of embodiments, various decalcification and/or fluid heating components 1700 of a steam generator system can include a boiler 316, where the system further comprises a (e.g., sub-boiling) a pre-heater (e.g., a pre-heat chamber) 310 and a filter assembly 312 between the water reservoir 18 and the boiler 316 for purposes described below. According to various embodiments, a component configuration 1700 for a steam generator can include the pre-heater 310, the filter assembly 312, a water (or any other fluid) pump 314, and the boiler 316. All disclosed arrangements and embodiments display a particular arrangement of components, but it is also contemplated that each embodiment can alternatively include some or all shown components arranged in any other order. Each of the components, above, is described in greater detail, herein.

[0094] During the appliance operation, the water pump 314 will cause water to flow along the system from the water reservoir 18 to the boiler 316, where it can boil and turn to steam. Depending on the appliance operation, the steam can immediately leave the boiler 316 and travel out the iron 14, or it can accumulate in the boiler 316 or elsewhere until the user activates a steam function. Is it noted that iron 14 is merely an example of a steam delivery device, which can alternatively include a garment steamer head, or any other known or developed steam delivery device.

[0095] According to various embodiments, the pre-heater 310 receives a flow of water from the water tank and raises the temperature to preferably about 60-99 °C (i.e., below the boiling point of water), more preferably to 70-90 °C, but in some cases 100 °C or greater. In some embodiments the pre-heater 310 can heat to water to 100 °C or above. At above 60 °C, dissolved calcium carbonate in the water can precipitate and form solid particulates within the pre-heated, but preferably not, but optionally boiling, water. In other words, the calcium carbonate found in the water being heated is kept in the water, but converted from a dissolved form to a particulate form, suspended in the heated water. In some embodiments, a non-stick (e.g., PTFE, etc.) coating may be applied to the walls of the interior cavity 311 (or otherwise made to be composed of a non-stick substance as used herein) of the pre-heater 310 to resist precipitated calcification from adhering to the walls of the pre-heater 310. The filter 312 is operatively located after the pre-heater 310 so it can trap and collect the solid particulates from the water, preventing them from reaching the boiler 316. Water can be moved along fluid connections provided between the various components, and the pump 314 may preferably be located between filter 312 and boiler 316. Pump 314 (or other pump(s)) can be located elsewhere so long as water flow is provided from water reservoir 18 through to boiler 318, as needed.

[0096] As shown, the filter assembly 312 is operatively located after the pre-heater 310 so it can trap and collect the solid particulates from the water, preventing them from reaching the boiler 316. Water can be moved along fluid connections provided between the various components, and the water pump 314 may preferably be located between filter assembly 312 and boiler 316. Water pump 314 (or other pump(s)) can be located elsewhere so long as water flow is provided from water reservoir 18 through to boiler 316, as needed. A gravity feed may also be used, for example, to supply water from reservoir 18 to pre-heater 310.

[0097] Filter assembly 312 can include a filter cartridge 319 that can include one or more filter elements 315 and filter structure 328, which can include structural rib(s) 313. The filter elements 315 and the filter structure 328 together can be removed from the filter housing 330 as the filter cartridge 319. The filter element(s) 315 (and optionally the filter structure 328) can then be preferably emptied, rinsed, cleaned, and/or washed, and replaced for continued use. In one embodiment, simply removing the filter elements) 315 and filter structure 328 as the filter cartridge 319, turning them over, and running tap water over the unit can substantially empty and clean the filter components of the filter cartridge 319. The filter element(s) 315 can comprise a stainless steel (or similar) mesh material, and may have a mesh pore size of about 20-200 microns, in various embodiments. The size of the mesh openings can be smaller or larger, but is preferably sized based upon the effective size of the precipitate that results from the pre-heating. A disposable filter element 315 can instead be used.

[0098] Various steam generation components can be fixed within the interior space of the steam generator base 12 in any known or developed manner. In various embodiments, one or more water pumps 314 can be utilized for assisting in the fluid flow of either the water or steam as may be desirable or necessary. Also, additional filter assemblies 312, filter cartridges 319, filter housings 330, and other water treatment components can be included. Examples of filter elements 315 can include cylindrical, planar, and various other suitable shapes, sizes, and types of filter elements 315, especially filters configured to separate particulate calcium carbonate or other calcification from water being filtered. Filter elements 315, as used herein, can preferably include three-dimensionally usable filter elements 315, where a total amount of filtration can be a function of the volume of the filter elements) 315 of the filter cartridge 319 in use.

[0099] One advantage of described pre-heating systems is that they can increase the useful lifespan of the various steam generator components (in particular boiler 316), as solids will be less likely to accumulate on the interior walls of the boiler cavity 317, which presently reduce boiler 316 performance and life. The advantages of the pre-heat/filter based systems can be further improved by implementing a non-stick substance 1710 on interior walls of the pre-heater 310. Optionally, a similar non-stick substance 1712 can be applied to inner walls of the boiler 316. Boiler 316, if otherwise strained by excessive calcium carbonate solid build-up, can become overworked, overheated, or otherwise malfunction or wear. By reducing solids build-up in the boiler 316, and instead catching the solids in the filter assembly 312, the filter assembly 312 can collect the solids, in a unit designed to do so. The combination of pre-heater 310 and filter assembly 312 may also prevent solids or particulates from travelling to the iron 14 and clogging up the iron 14, its soleplate holes, or discoloring the garments. In various embodiments, and as described herein, various other steam delivery devices can be substituted for iron 14.

[00100] Advantageously, the components of filter cartridge 319, including the filter element 315 and filter structure 328 that together fit within the filter housing 330, is preferably cleanable and reusable. Filter structure 328 preferably supports a number of filter elements 315 using structural rib(s) 313. The filter elements) 315 can comprise mesh panels in an arrangement around the filter structure 328 for particulate filtration from the water. The mesh size of the filter elements 315 can be based on particulate size. In preferred embodiments, water including particulates can be controlled to flow from filter inlet 326 to filter outlet 332 of filter housing 330 from an inside of filter element 315 to an outside, where the water once reaching the outside of the filter element 315 will have its particulates already filtered out of the water. As described herein, the filter assembly 312 components can take a cylindrical, inside-out water flow configuration (described above), as shown, or the filter assembly 312 may take any other suitable shape, such as a flat, planar filter configuration, among others. In this way, solids will be captured within and potentially fill the inside volume of the filter elements) 315 and filter structure 328 of the filter cartridge 319. [00101] A schematically-shown water source 346 can include water reservoir 18 or any other water source 346, as applicable. Water source 346 is fluidly connected and in fluid communication with pre-heater 310 via pre-heater inlet 320 and fluid conduit 348. Water source 346 and/or fluid conduit 348 can also include various components, such as additional pumps, filters, junctions, heaters, etc. Once water from water source 346 reaches the preheater 310, the water can completely or partially fill a pre-heater cavity 311 defined by walls 318. An example of a pre-heater heating element 322 can be approximately shaped as a partial toroid, and can be attached to a lower side of pre-heater 310. In this case, heat is conducted through the wall 318 to within the pre-heater 310 to heat the water.

[00102] In some embodiments, the location of the heating element 322 (whether inside or outside the pre-heater wall 318) can affect the heating distribution of the water contained in the pre-heater 310 at a particular point in time. According to various embodiments, the heating element 322 can be located on a surface of the pre-heater 310. Heating element 322 can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating elements), a tube heating elements), combinations thereof, among other types of heating elements, as known in the art or developed. Preferably, the heating elements are controllable so that water contained in the pre-heater will not reach a boiling point (but in some cases may reach a boiling point), but may be controlled to be heated to various temperatures. Any number and/or location of temperature, fluid flow rate, or volume sensors can be incorporated for controller 360 use.

[00103] Control systems (including controller 360, which can be similar to controller 501), as known, can be included to manage and maintain a desired water temperature within pre-heater 310. For example, using various control systems, water temperature can be determined (and the water heated) as a function of heat applied to a present, past, or future flow rate of water. In preferable embodiments, the water can be heated in a continuous heating process at the pre-heater 310 and/or the boiler 316 meaning the water can enter the pre-heater 310 at a supplied temperature (likely ambient) from the water source 346 and at a flow rate, the water can be heated as it flows through or along the pre-heater 310 at the flow rate, and the water can exit the pre-heater 310 at a desired temperature to cause precipitation of the calcium compound from the water at the same flow rate. Alternatively, the water can be heated in stages or all at once as the water is supplied at a desired volume on a cycle by cycle basis. [00104] Once water from water source 346 is pre-heated at the pre-heater 310, the pre heater outlet 324 may fluidly communicate the water and precipitate to filter assembly 312 by fluid conduit 350. The water can enter the filter assembly 312 by filter inlet 326, and the water may then pass through filter housing 330, and filter element(s) 315, which may preferably be supported by filter structure 328. Filter element(s) 315 can be size, configured, and/or controlled to have a maximum water flow rate that exceeds typical need when the filter element 315 is relatively free of particulates and to allow for cases where filter element 315 is partially clogged with calcium carbonate (or other) particulates caught in pores of the filter element 315 (e.g., pore size of 20-100 microns or any other suitable pore size). In some embodiments, the filter element 315 of the filter cartridge 319 has a filter volume that fills with particulates as the particulates are filtered from the water flowing through filter assembly 312.

[00105] Preferably, filter structure 328 and filter element 315 are removable as a unit from filter housing 330, whereby the filter components can be emptied, cleaned, rinsed, and/or washed by a user or consumer. After removing and cleaning the filter components, the filter element 315 and filter structure 328 can be replaced back into the filter housing 330 of filter assembly 312. In alternative embodiments, various replacement components (e.g., filter element 315 and filter structure 328 individually, or together as filter cartridge 319) can be purchased in place of cleaning, especially, e.g., if the particular parts have been in heavy use for substantial amounts of time.

[00106] As shown in Fig. 17, once the water has been filtered by filter assembly 312 and the particulates removed from the water, the filtered water can exit filter outlet 332 and enter the water pump 314 at pump inlet 333. The filter outlet 332 can be configured to be in fluid communication with the pump inlet 333 by an operative connection such as fluid conduit 352. Fluid conduits, as used herein, can include any suitable hose, conduit, conveyance means, connection, etc. capable of carrying and/or transferring a liquid and/or fluid, and that can be fixed in place by conventional means including clamps and the like. Fluid conduits can include various fluid, operative, and other connections.

[00107] Water pump 314 can include a pump housing 336 and a pump motor (not shown), which can be an electric motor, preferably. Water pump 314 can be controlled by a user or a controller (e.g., controller 360) according to various embodiments. For example, water pump 314 can be activated to pump water into boiler 316 when boiler 316 is empty, low, or when a user has begun using the steam generator and/or steam station, among other circumstances.

[00108] The water pump 314 is shown in fluid communication with the boiler 316 via fluid conduit 354. Fluid conduit 354 is connected to the water pump outlet 334 and the boiler inlet 338. Boiler 316 includes a boiler housing 344, a boiler cavity 317, and a boiler heating element 342. Boiler 316 can also optionally include a non-stick substance 1712 on walls of the boiler cavity 317 to reduce occurrence of build-up on the boiler cavity 317 walls. The boiler heating element 342 can be similar to the pre-heater heating element 322, or can be configured and/or controlled differently. In some embodiments, the boiler heating element 342 is located outside the boiler chamber 317, but in contact with boiler housing 344. Heating element 342 can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating elements), combinations thereof, among other types of heating elements, as known in the art or developed. Preferably, the heating elements are controllable so that water contained in the boiler 316 will reach the boiling point of water to generate steam. As described above, any number and/or position of temperature, fluid flow rate, or volume sensors can be located within the system.

[00109] The boiler 316 can be controlled to maintain an amount of steam when activated, awaiting only a user’s input, such as an activation of steam through steam generator controls or switches, and having a nearly instant supply of steam when desired. In alternative embodiments, the boiler 316 can remain idle when the user is not steaming garments, or may merely pre-heat the water while awaiting further instructions prior to heating water contained in the boiler chamber 317 to the boiling point of water (e.g., 100 °C). In some embodiments, the boiler 316 can received about 10-40 grams or ml of water from water pump 314 at a time, as a cycle. Likewise, the pre-heater 310 can receive a similar amount (10-40 g) of water per user steam cycle or operation. In other embodiments, the pre heater 310 and/or the boiler 316 can receive a constant or steady supply of incoming water and can continuously heat the water to create steam and/or water vapor.

[00110] Steam can be caused to exit the boiler 316 via boiler outlet 340, which itself can be in fluid communication with a steam exit 358 via fluid conduit 356. Steam exit 358 can be connected, for example, to a steam delivery device such as iron 14, whereby the steam can be applied to a garment. The steam will preferably have little to no calcium carbonate that reaches the garment, as described. If iron 14 is used, the iron may have a control function whereby a user can choose a free flow or steam or a set steam cycle. In other embodiment, the steam flow may be determined automatically, for example, based on preset parameters or circumstances at controller 360.

[00111] In some embodiments, the various steam generator components (e.g., pre heater 310, filter assembly 312, water pump 314, or boiler 316) can contain varying amounts of fluids such as air or non-steam gas. For example, following pre-heating of water at the pre heater 310, the heated water can proceed to filter assembly 312, but the filter assembly 312 may not be completely full with the pre-heated water. Therefore, filter assembly 312 can operate even when not fully filled with the pre-heated water. Some degree of air in the system, including at the filter assembly 312, can be accommodated and may not substantially reduce the performance of the various components described, herein. In other embodiment, the system can be controlled to be completely filled with H ₂ 0, including water, water vapor, and/or steam in various locations. Some air can be present in the steam generation system without substantially affective performance, although a full system may be optimal for pumping or steam generation performance.

[00112] Fig. 18 is a flowchart of a process 1800, according to various embodiments. The process 1800 can be in accordance with the description and structures of Figures 1-17, described herein. According to various embodiments, process 1800 is a method of making a steam generator or steam station.

[00113] Process 1800 can begin by providing a water heater having an interior surface and configured to heater water such that steam is produced at operation 1810. Process 1800 can continue by providing a non-stick substance as at least a portion of the interior surface, the non-stick substance configured to reduce adhesion to the interior surface with respect to a calcium compound within the water, where the calcium compound in the water is caused to flow out of the water heater as calcium compound solids at operation 1812.

[00114] Process 1800 can continue by providing a filter assembly in fluid communication with the water heater, the filter assembly including a removable particulate filter element configured to filter out at least some of the calcium compound solids received from the water heater at operation 1814. [00115] In one particular experiment of the present invention by Applicant, when water with 200 parts-per-million (PPM) calcium concentration was heated and filtered according to embodiments of this disclosure, water exiting the water heater was found to have only 60 PPM calcium concentration in the stream, a reduction of about 70% of the calcium previously in the water entering a steam station.

[00116] It is noted that while it may be preferable for various pre-heater devices as described herein to heat received fluid (e.g., water) to approximately 60 °C, even if water were to boil in a pre-heater, precipitated particulates/solids would still be beneficially separated from the fluid in question.

[00117] As noted in several embodiments, following a pre-heater apparatus (or optionally a boiler unit) a filter system can be implemented to collect precipitated particulates. The filter system can include a removable filter, a permanent filter, a pre-heater system configuration that stores the precipitated particulates and is user-cleanable, etc.

Multiple possible configurations for capturing and removing the particulates from the system are contemplated.

[00118] Also as noted herein in various embodiments, a non-stick (or stick-resistant) layer can be applied on inside surface(s) of various pre-heater and/or boiler units to prevent particulates from sticking to the pre-heater walls, and thereby allowing the particulates to travel to a downstream filter, which can collect the particulates.

[00119] Various mechanical configurations are contemplated. In particular, one embodiment includes all separate components, such as separate and individual pre— heater, filter, and boiler components. Therefore, a steam generator base unit can include a water reservoir, a pump, a pre-heater, a filter, and a boiler, and a steam generator iron unit can be separate. In another embodiment, a pre-heater and filter system can be combined into a single unit with a separate boiler. In another embodiment, a filter system and boiler can be combined into a single unit, and the pre-heater system can remain separate and individual. In yet another embodiment, a pre-heater, a filter, and a boiler system can all be integrated into a single assembly.

[00120] In addition, various embodiments that employ a pre-heater can include configurations where the pre-heater is either horizontally or vertically mounted. In preferable embodiments, physical components can be placed between a pump and a boiler unit of an existing steam generator system.

[00121] Non-stick substances, coatings, etc. as used herein can alternatively be formed as one or more non-stick components that contact with liquid or water during heating. For example, in a case involving an example pre-heater, a tube can be a non-stick component implemented for non-stick purposes within the pre-heater. Non-stick components can take the form of cylinders, or other shapes that can be applied to, inserted into, or used with various water heaters, boilers, pre-heaters, and other fluid-exposed tubes and connections as used herein. A non-stick component can be formed such that an internal contour of a water heater is contoured by the non-stick component once formed, inserted, etc. Therefore, non-stick substances can be performed prior to implementation, and can be combined with, used with, and/or attached to various components described herein.

[00122] Although various embodiments herein have been described with respect to steam generator systems, other machines and/or appliances can also benefit from improved anti-calcification improvements resulting from described embodiments. For instance, beverage makers or brewers (such as coffee makers), water heaters of various kinds, such as household or commercial, hand-held iron units themselves, humidifiers, dehumidifiers, among many others.